Another issue with my 600. It's a 2004.5. Was out last night and the battery light started flashing and my headlights started going bright then dim. I got it home and checked with a multi meter and when running getting 18 volts. Was told it was the regulator I put a new one on and now it reads 12.6 doesn't change when reved up. It also will not run with battery disconnected. I checked the voltage on the 3 yellow wires from stator when running and none give more than 5 volts even been the battery reads 18. I'm kinda confused by this

 

Weird transition year model on this 600.. Between Y1,Y2,Y3 should show around 18 vac +/- 20% at 1300 rpms. Possibly a stator problem if it's showing less,plus another problem is having the correct regulator. 2004 models had 3 regulators depending on the build date of the atv. The latest one(supposedly for the 2004.5 model) is expensive. The 2005 model 600s had the ecm module instead of a regulator. Item#23.2004 Polaris A04CH59AK SPORTSMAN 600 (A04CH59AK/AL/AN/AQ/AW) Electrical/Taillight | Cycle Parts Warehouse

 

Shouldn't it still run if I disconnect the battery

 

NO.. These were the first of the dci ignitions that had to have voltage to the cdi to run. Older models like the 325/330,425 and 500 had the old magneto triggered ignitions and could recoil start without a battery and stay running.

 

With the old regulator when I started it would read 13 volts and creep up to 18 volts. I bought a new ricks motor sports one and now when I start it the voltage stay at 12.5 and doesn't move even when reved. Sounds like I got a bad regulator

 

Could be a bad regulator,BUT find your build date. Your vin # to a dealer and and they can tell you. May take that expensive updated regulator.Even ricks shows three different stators and 2 different regulators.https://ricksmotorsportelectrics.com/results/

 

I looked it up on ricks website and it says part#10-558 replaces 4010929

 

Then Ricks should know.. Give em a call and tell them the problem you have. They should be able to help. I used their stators before and only had one where the pick up coil wires were reversed in the connector. They shipped a new one over night to replace it. Good company at least when I dealt with them.

 

So I now have power coming from the regulator. I put the volt meter on the red wire off the voltage regulator and getting 8 volts at idle and 14 if I rev it up. But yet still doesn't show on the battery. Battery shows 12.7 motor off and 12.4 motor running and still flashes battery light

 

Check all your connections on the regulator. If these are all ok,looks like you're going to be chasing a short or possibly a bad ground.